Ergodyne
www.ergodyne.com

Windpower Engineering & Development

“I’m focusing on the power grid and how it interfaces to wind,” Smith said. “I’m trying to help engineers, especially younger ones, understand how to do this, because there are relatively few standards that tell you.”

Smith’s experience working for utilities such as the Tennessee Valley Authority and Georgia Power Company has made him a natural liaison among different wind power-related stakeholders, especially in the southeastern U.S., where wind energy has yet to make major inroads. For example, he organized a wind energy round table in 2010 for Atlanta-based Southern Company that brought together technical, financial, industry and utility experts for two days of presentations and discussions about wind power.

“I think it’s important for utilities to understand how wind turbines work, even if they’re not currently working on them,” Smith said.Smith’s technical expertise was also instrumental in the development of ORNL’s Wind Energy Data and Information (WENDI) Gateway, an online clearinghouse for wind energy-related information and data. The WENDI site, which is available to the public at http://windenergy.ornl.gov through support from DOE’s Energy Efficiency and Renewable Energy Office, houses two main interfaces: the Wind Energy Metadata Clearinghouse and the Wind Energy Geographic Information System (WindGIS).

“You can even use this tool for the logistics of moving wind turbine components from the manufacturer to the site,” Smith said. “The tool helps look at all factors at once when you start thinking about siting.” Smith is a senior member of IEEE, active in several wind-power-related working groups in the organization, and has co-authored dozens of papers published by IEEE.

He holds a bachelor’s degree in electrical engineering from the University of Tennessee, Chattanooga, and two associate’s degrees from Chattanooga State Technical Community College.

Windpower Engineering & Development

Selected executives from across the nation will join the program. Targeted executives are those who have built successful companies in different sectors such as aerospace, biotechnology and enterprise technology. Executives with more than 20 years of experience, an advanced degree and experience leading a venture-backed start-up company are encouraged to apply. Each candidate must have a strong desire to transition into the cleantech industry through accelerated training, networking and technology exposure.

“Colorado is a hub for cleantech. There is an abundance of market-ready research and technology here to drive the success of this program,” said Wayne Greenberg, director of the Cleantech Fellows Institute. “The executives selected will have access to virtually unlimited resources, build an invaluable national network of cleantech stakeholders and have the opportunity to launch venture backed companies in one of the industry’s most innovative and supportive communities.”

“We’re thrilled to be a founder of the CFI and we look forward to working closely with experienced executives who can incorporate fresh ideas into leading successful cleantech start-ups,” said Christine Shapard, executive director of Colorado Cleantech Industry Association. “This will be the first year of the program and I’m confident that it will prove to be one of the nation’s most practical and motivating programs to advance the cleantech industry.”

CFI was created by the Colorado Cleantech Industry Association (CCIA) and is supported by the Department of Energy’s (DOE) National Renewable Energy Laboratory (NREL) and Advanced Energy Economy (AEE), a national business organization of which CCIA is a founding chapter. The CFI program builds on a regional program developed by the New England Clean Energy Council, another AEE member, and takes it national in scope.

This new program begins on Sept.17 with executives immersed in a highly interactive curriculum. Eight weeks of the 17-week program will be held on-site at various locations throughout Colorado such as the Colorado School of Mines, University of Colorado, Colorado State University and NREL. Seven weeks will be held “virtually” as webinars taught by nationally recognized experts in advanced energy. The executives will also participate in valuable networking events such as evening debates, speaking sessions, and exclusive dinners.

Approximately 20 percent of the program will be dedicated to intensive study of the energy industry and the regulatory, capital and structural challenges the industry faces. Topics will include overviews of wind, solar, renewable fuels and electricity markets, as well as the state of venture deal terms in cleantech and the outlook for exits. The participants will also study which industry niches are securing the most venture investment to best position their companies. Areas of in-depth study include advanced transportation technologies, energy storage, clean energy technologies and energy efficiency and building technologies.

The key to the program’s success will be the executives’ exposure to commercial-ready technologies from Colorado sources. Working with the universities and NREL as well as various business incubators such as CleanLaunch, the executives will develop a deep understanding of the technologies being researched at each institution. Each executive will select a technology that sparks their interest and plan a capstone project to present in January, in advance of graduation on Jan. 11, 2013. The capstone project includes a market and technology assessment as well as the building of an initial business plan for a potential new cleantech company.

“One of the challenges in the advanced energy sector is finding the right talent to turn cutting-edge technologies into successful companies,” said Graham Richard, CEO of Advanced Energy Economy. “The Cleantech Fellows Institute is a perfect example of identifying special individuals outside of the clean energy industry – whether that be technology or other sectors – and helping them acquire the expertise they need to succeed in the dynamic, competitive advanced energy marketplace. We’re very proud to support this program, which is the result of a true collaboration between two of our founding state partners.”

Cleantech Fellows Institute
cleantechfellows.com 

Windpower Engineering & Development

Hubbell Power Systems
www.hubbellpowersystems.com

Windpower Engineering & Development

So what should be monitored as the inspection approaches, and what is the best method for effective condition monitoring? Consider a few options for a typical MW-class wind turbine.

Main bearing

The repair of the main bearing typically involves removing the hub. With vibration analysis condition monitoring, the lead times to bearing failure are often quite long, on the order of several months. This is largely in part due to the slow speed and intermittent operation. Grease analysis is one method to determine the condition of the bearing. Other conditions (such as imbalance for example) cannot be detected with grease analysis. So with arguably one of the most expensive repairs on a turbine, end-of-warranty inspection must be addressed.

According to those who have performed end-of-warranty inspections, grease analysis gets mixed results. The main-bearing temperature from SCADA sweeps might be helpful but it is hard to determine the severity of damage from such data. Hence, main bearings must be examined in an end-of-warranty inspection.

Gearbox

The accompanying table (next page) shows common inspection techniques for a turbine gearbox. There is a significant difference between which worn components can be detected with a bore scope and a vibration-analysis inspection. A bore scope doesn’t address the main bearing, generator, or correctible conditions such as misalignment, imbalance, looseness, generator lubrication, and electrical shorting. Despite these gaps in detection, it is still considered the standard practice for end-of-warranty inspections.

Repairs in the planetary section and low-speed shaft (LSS) usually require a crane call-out. Repairs in intermediate and high-speed shafts (HSS) of some models can be performed up-tower for a fraction of the downtime and crane cost. Oil analysis also can help, especially when the testing looks for a proper moisture content, total acid number, viscosity, and particle counts.

“You get a full picture of the condition of a drivetrain using a bore scope and vibration together,” says Upwind Solutions Director of Quality Control Russell Leach. “They complement each other to give a 360 degree view of the gearbox health.”

Generators

Not much is done on a generator in typical end-of-warranty inspections. Hence, it’s a good idea to use vibration analysis on it. “Vibration analysis makes detecting major failure modes in the generator a piece of cake,” says Don Roberts of B9 energy. “Resistance testing usually requires manufacturers’ approval beforehand.” Common generator issues (electrical shorts and bearing failures) were detailed in a previous condition-monitoring article on generator condition monitoring (Windpower Engineering & Development, November, 2011).

The best methods for ensuring that a turbine will enter post warranty in optimal condition are those that give the manufacturer and owner a clear and thorough picture of the turbine’s condition. “The renewable energy or production tax credit is paid when the turbines are reliable and productive,” says Roberts. “To ensure reliability, install a permanent condition-monitoring system within 12 to18 months prior to the end of warranty. This enables “alarming,” and a sufficient data stream to support claims and maximize the value of a condition-based monitoring system,” adds Roberts. WPE

By: David Clark/Condition Monitoring Consultant

Windpower Engineering & Development

PSI Repair Services says it offers fast, affordable repairs, including upgraded/longer-life products, for out-of-warranty electronic, hydraulic and precision mechanical components that drive your turbines’ pitch and yaw systems and down tower electronics. Components repaired include printed circuit boards, PLCs, control cards, VRCC components, IGBTs, thyristors, converters, pitch motors, hydraulic pumps, servo motors, transducers and much more. All repairs come with a free evaluation and one-year warranty.

The company uses diagnostic tools to detect failures down to the microchip level. Solutions range from minor component changes to full replacement printed circuit boards, with enhanced designs to improve performance and reliability. These options allow significantly increasing mean time between failures (MTBF) and prevent costly downtime and/or repeat repairs.

In addition, PSI provides comprehensive remanufacturing services for unsalvageable, obsolete components. Plus, PSI’s stocking programs provide fast turnaround to help reduce inventories.

The WINDPOWER 2012 Conference & Exhibition takes place June 3-6 at the Georgia World Congress Center in Atlanta, GA. PSI Repair Services will be exhibiting in Booth 1062.

PSI Repair Services
www.psi-repair.com 

Windpower Engineering & Development

Hendrix Spacer-Cable systems feature a compact configuration and reduced requirements for clearance which means multiple circuits (lines) can be installed on a single pole.

overhead on poles. When a conventional pole carries its max number of lines, the local electrical company has several options. The experience of a small electrical cooperative is useful in understanding the general transmission problems in a growing community, and a few solutions.

The problems
Fort Loudoun Electric Cooperative (FLEC) faced the challenge of keeping up with the growth in its area. According to Chad Kirkpatrick, VP of Operations and Engineering, the mountainous Tennessee geography and limited rights-of-way required looking for alternatives to traditional open-wire structures, especially at substation exits. One solution selected was a cable-spacing system that features a compact configuration that reduces clearance requirements for wire on poles.

The cooperative gets power from more than 3,200 miles of line, and a mix of nuclear, coal, hydro, solar, and wind power provided by the Tennessee Valley Authority.

The fix
FLEC had used spacer cable in the 1970s to under-build a congested area, letting engineers add a new line by weaving it through the area without having to reconstruct the existing open-wire structure. The spacer cable was supplied by Hendrix, a New Hampshire-based firm that provides underground cable, cable spacers, tree wire, insulators, and other overhead transmission-pole products.

The spacer-cable system solves several tight space constraints. Kirkpatrick cites three reasons that it’s a good selection. Limited right of way is the driving factor because there is no way to obtain additional land for more open wire circuits. Second, the spacer cable gives designers flexibility with the number of circuits in the right-of-way corridor along with configuration and clearance requirements. Finally, the spacer cable allows use of existing poles. “We do not want to have to change poles, and it is relatively easy to add an additional circuit on an existing line using spacer cable,” says Kirkpatrick.

The power lines exit a substation serving a mountainous Tennessee community. Limited right of way is a big challenge when putting up new power lines because there is no way to obtain additional land for more open wire circuits.

Because much of the service area is in the foothills of the Smoky Mountains, FLEC tends to leave hardwood trees close to the circuit. So, falling softwood trees tend to be caught by the hardwood instead of falling on the line. FLEC still maintains clearances, but not as much as are needed with conventional open wire structures.

A closer look
Spacer-cable systems feature a compact configuration and reduced requirements for clearance which means multiple circuits (lines) can be installed on a single pole. Over or under-building spacer-cable systems in substation exits can greatly reduce the cost of adding capacity.

A spacer-cable system includes a messenger cable that supports the structure. For high-speed current collection, it is necessary to keep the contact-wire geometry within defined limits. This is usually accomplished by supporting the contact wire from above with a second or messenger wire. Its mechanical strength makes it suitable for long spans and it also serves as system neutral and lightning shield.
The system also includes polyethylene spacers to keep cables from rubbing and wearing.  A series of spacers are clipped to the top of the messenger wire. The spacers support, separate, and clamp the phase conductors in a triangular or diamond-like configuration.

Spacers, placed between spans every 30 to 40 feet, install and come off easily. No ring ties are required. A built-in clamp accommodates a full range of conductor and messenger sizes. A wedge-shaped messenger hook provides maximum grip.

The spacers also have good weather-washing characteristics and their design provides high strength against short circuits. They are highly resistant to shock, impact, and rifle fire, and can be installed with hot-line tools.

Covered conductors consist of stranded, hard-drawn aluminum with three extruded layers, the thickness of which depends on a voltage rating. Hendrix’s proprietary, high density outer layer resists abrasion, electrical tracking, and UV degradation.

Also, reduced phase spacing is possible due to a three-layer covering that withstands temporary contact with tree branches and other vegetation, thus reducing outages and improving power quality. Along with the compact configuration, the system greatly reduces need for vegetation removal during circuit installation, thereby significantly trimming tree-trimming costs. The covering also protects wildlife from exposure to lethal currents.
Hendrix
Hendrix.com

Windpower Engineering & Development

To understand the challenges ahead, first consider what FERC is trying to “fix.” The Commission concluded that the lack of a requirement for transmission providers to consider transmission needs at the local or regional level driven by public policy requirements—such as clean energy requirements—made its existing transmission planning requirements inadequate. In remarks about the rule, FERC Chairman Jon Wellinghoff recognized a changing mix of generation resources seeking to use the transmission system. In fact, even the Open Access Transmission Tariffs (OATTs) for centralized markets in certain states with RPS standards, ISO-New England and PJM for example, do not yet specifically provide for public policy-driven transmission projects. FERC also concluded that there were few existing procedures for identifying and evaluating the benefits of interregional transmission projects. The rule also eliminated the right of first refusal (ROFR) in OATTs under certain circumstances. In certain regions, independent developers have attributed difficulties constructing certain types of transmission projects to ROFRs granted to incumbent transmission providers.

Order 1000 requires transmission providers to revise their OATTs to include a process for identifying transmission needs driven by public policy requirements, and for evaluating possible solutions. Order 1000 does not mandate that transmission be built for public policy purposes.

Also, transmission providers’ OATTs will now include a process to allocate the costs for such a project. The rule establishes guiding cost-allocation principles consistent for all regions with the central concept being “beneficiary pays.” One such principle is that an acceptable cost allocation proposal would allocate costs for new transmission facilities in a manner that is at least “roughly commensurate” with the benefit received by those who will pay these costs. Consistently, the principles also provide that entities that receive no benefits from transmission projects should not be allocated costs for those facilities. FERC’s principles for regional and interregional cost allocation do not mandate how beneficiaries are to be identified or which cost-allocation methods should be implemented. A transmission provider could rely on the same cost allocation for market efficiency, reliability, and public policy transmission projects.

Order 1000 is not a fill-in-the-blank rule, so its implementation will be intense and contentious. Submittals on regional transmission projects are due to FERC by October 11, 2012.Order 1000 noted that FERC is not seeking to undermine progress already underway or already accomplished. Those centralized markets (ISOs or RTOs) with transmission planning procedures in place that take public policy objectives into account will likely have the smoothest compliance, and their existing methods will likely continue. For example, Midwest ISO (MISO), Southwest Power Pool (SPP), and California ISO (CAISO) have provisions to consider public-policy projects, including cost allocation provisions, and may not have to make significant revision to their OATTs. Thus, MISO, SPP, and CAISO may implement the rule’s requirements quicker.

For regions outside an ISO or RTO, the first step, identifying a region, may be challenging. In addition, transmission providers outside centralized markets will need to propose how they will allocate project costs within the region, once it is identified. In areas of the country where there are no RPS requirements, FERC might accept a less detailed plan for considering public policy driven processes.

Compliance submittals do not immediately become effective upon filing with FERC, and proposed tariff changes must be accepted for filing by FERC order. The Commission has stated that if stakeholders cannot reach consensus or near consensus during a compliance period, the FERC will resolve compliance issues. This may incent compromise. There is a real opportunity for states to lead the way among stakeholders on consensus proposals.

Transmission providers must return to FERC with their interregional plans by April 11, 2013. As to interregional efforts, best practice is for transmission providers to proceed simultaneously with the interregional and regional efforts rather than wait to consider interregional plans until the October 2012 regional submittal has been made. Interregional issues may be particularly difficult outside of an ISO or RTO context. However, interregional transmission planning and cost allocation will likely be less formal than the regional process, possibly allowing transmission providers with more flexibility on the level of detail included in their FERC submittal.

FERC may issue a subsequent order(s) that modifies Order 1000. Therefore, in addition to the implementation hurtles that result from developing the compliance filings and FERC processing the compliance filings, there is a chance that FERC could clarify, modify, or even reverse some of its findings in Order 1000.

Over 60 entities, including transmission providers, transmission customers, state commissions and industry trade groups, have asked FERC to change course. Also, those who asked FERC to change course may appeal Order 1000 to the U.S. Court of Appeals asking the court to take action. However, a court decision on appeal of Order 1000 could be years away. In the interim, unless and until the FERC or a court decides to stay the effectiveness of Order 1000, the rule remains effective.

The combination of eliminating certain ROFRs, the mandate to consider public policy requirements, and the requirement for interregional planning should lead to increased opportunities for transmission investment, particularly for bringing location-constrained renewable resources onto the grid. Therefore, the long-term outlook for public policy-driven transmission projects is favorable. The shorter-term outlook is more challenging outside regions that have already made progress in this regard. It may be a long process before ISOs and other regions have effective cost allocation proposals for public policy projects in place. However, once the process is complete and cost-allocation methods are in place, additional certainty will likely spur investment in transmission. With a long lead-time for compliance filings and FERC consideration and approval, it may be more attractive in the shorter term for developers to consider merchant or participant-funded transmission projects to the extent that defined cost allocation rules are not already in place. WPE

By: Cathy McCarthy, Co-head of Dewey & LeBoeuf’s Energy Regulatory Department www.deweyleboeuf.com

Windpower Engineering & Development

The filter element captures particles at 3 micron absolute (β3≥200)

Hydroguard hybrid breather can stand up to a wide variety of industries and applications. The breather is outfitted with an expansion chamber to isolate lubricants from all levels of ambient humidity. A clear, rugged polycarbonate casing allows for viewing desiccant as it changes color, indicating that the breather should be replaced. Check valves ensure no excess pressure/vacuum builds. Des-Case hybrid breathers attack the source of contamination, allowing your equipment and lubricants to run longer and harder. As wet, contaminated air is drawn through the unit, multiple 3-micron polyester filter elements remove solid particulate and the color-indicating silica gel extracts moisture. The diaphragm allows for expansion and contraction of the air in the casing as a result of temperature variations during steady-state operations. When air is expelled from the container, the top foam pad prevents oil mist from contacting silica gel or entering the atmosphere. The hydrophilic agent is partially reactivated by the dry air passing back through.

DES-Case
www.descase.com

Windpower Engineering & Development

President of Gearbox Express Bruce Neumiller talks with Chris Schoenher from the Wisconsin department of administration.

A new company, Gearbox Express (GBX), along with state and local public officials, recently celebrated the official grand opening of its new 43,000 ft² facility in Mukwonago, Wisconsin. The company says it is the only one in North America focused on providing independent, down-tower, wind-gearbox remanufacturing services. They are expected to eventually employee 100 people.

While GBX understands the overall tone of the wind energy industry is considered flat, it is confident that by helping develop the aftermarket infrastructure, they’ll impact job growth and the economy.

“There are more than 26,000 active turbines in the United States and it’s a fact that the gearboxes will need replacing during their lifetime,” said company CEO Bruce Neumiller. “Wind farm owners want their investments to keep running so there’s a tremendous opportunity for us to help protect and manage their assets.”

The three wind-industry vets that started GBX succeeded in attracting millions of dollars of investment capital along with a $3.4 million low interest, revolving loan from the Wisconsin State Energy Program.

A new gearbox is going in. Gearbox Exchange says it will keep an inventory of remanufactured gearboxes in its GBXchange program to allow for immediate swap-outs when they’re being removed from the turbine.

“The people at GBX have developed a business model that helps address a critical economic issue by bringing wind turbines back on-line much faster,” said Chris Schoehnerr, Deputy Secretary, Department of Administration for the state of Wisconsin. “A key element of Wisconsin’s past and future success is having driven entrepreneurs with technical manufacturing experience. That creates profitable new businesses and brings jobs to our state.”

The company says its climate-controlled facility offers a highly-flexible, technologically-advanced test stand that “rivals any in the world,” according to Neumiller. GBX technicians remanufacture the gearboxes to the latest revision level and then conduct a rigorous load test on its regenerative test stand. The test stand is a critical component of its business model and was the largest focus for investment. The company says it will keeps an inventory of remanufactured gearboxes in its GBXchange program to allow for immediate swap-outs when they’re being removed from the turbine.

“We are truly gearbox guys,” said Neumiller. “Our careful industry analysis work shows a clear need for an advanced company providing dedicated gearing, bearing, and gearbox expertise. And there is a critical need for one that uses the best equipment and parts.”

Gearbox Express
gearboxexpress.com

Windpower Engineering & Development